Folded Dry-Powder Inhaler Casing for Simplified Assembly
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Solution Overview
Problem
The manufacturing and assembly of unit dose dry powder inhalers are complex and costly due to the need for joining and handling multiple casing parts, which increases production complexity and expense.
Innovation Solution
A dry powder inhaler design featuring a single-piece casing with a hinge arrangement connecting two portions that can be folded together, allowing for simpler assembly and manufacturing, with flow directing elements and a lidding foil for efficient medicament delivery and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate casing parts are used to ensure proper components and dosage placement, then the inhaler functionality is guaranteed, but the manufacturing complexity and cost increase due to joining and handling multiple parts
Solution Approach 1:
The patent combines multiple separate casing parts into a single integrated casing structure that is molded as one piece. This single casing includes integrated features for holding the blister pack, positioning the flow director, and sealing the dose, thereby reducing the number of separate components from multiple parts to one unified structure that maintains all necessary functional capabilities.
Solution Approach 2:
The single molded casing serves multiple functions simultaneously: it provides structural housing, holds the blister pack containing the dose, positions the flow director, creates sealing surfaces, and defines the inlet and outlet pathways. This multi-functional design eliminates the need for separate components for each function, reducing assembly complexity while maintaining reliability.
2Ease of manufacture
If multiple separate casing parts are used to accommodate necessary components and dosage, then the inhaler can be properly assembled, but the production cost increases due to handling and joining multiple parts
Solution Approach 1:
The patent integrates multiple casing functions into a single molded part, eliminating the need for joining operations between multiple separate parts. This single-piece construction reduces manufacturing steps, lowers production costs, and simplifies assembly while maintaining the capability to properly accommodate and position all necessary components including the blister pack and flow director.
3Device complexity
If a single-piece casing is used to simplify manufacturing, then production complexity and cost are reduced, but the ability to properly position and secure internal components may be compromised
Solution Approach 1:
The single-piece casing incorporates locally optimized features at specific positions: recesses and engagement structures for securing the blister pack, positioning protrusions for the flow director, and sealed cavities for the dose. These localized structural variations within the unified casing ensure precise component positioning and secure attachment, maintaining manufacturing precision despite the simplified single-piece construction.
Data Source
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AI summary
A dry-powder inhaler (10) comprising a casing (19) is provided. The casing (19) comprises a first casing portion (11); a second casing portion (12); a hinge arrangement (40) connecting said first casing portion (11) and second casing portion (12). The dry- powder inhaler (10) is assembled by means of folding the first casing portion (11) and the second casing portion (12) together. The first casing portion (11) comprises a cavity (81) for receiving the lidding foil (95), said cavity being adapted to contain a dry- powder medicament. The first casing portion (11) and second casing portion (12) when folded together are adapted to form an inlet (9) for allowing a lidding foil (95) extending out there from and an outlet (8) for providing the medicament.